Transcript Demand-Side Management Technology Workshop: Motors and Variable Frequency Drives Sponsored by Basin Electric Power Cooperative with Western Area Power Administration April 6, 2009 Bismarck, ND www.johnsonconsulting.com.

Demand-Side Management
Technology Workshop:
Motors and Variable Frequency Drives
Sponsored by
Basin Electric Power Cooperative
with Western Area Power Administration
April 6, 2009
Bismarck, ND
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Deploying a Motors
Program
to Your Customers
Katherine Johnson, Johnson Consulting Group
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Web-based “How To” Guide
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Tips for Energy-Efficiency
Programs
• Post a link to MDM on your website.
• Include the MDM logo in your marketing materials
• Share motor management messages through existing
communications with your staff, contractors, and
trade allies.
• Provide regular and ongoing education for your
account managers, product design group, and other
internal
• Use MDM tools and materials – they’re FREE!
• Develop an outreach strategy to educate local trade
allies about the financial benefits of motor
management concepts.
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Empower Vendors
• Program staff or contracts educate vendors on the
financial benefit of motor management
• Assist vendors in offering motor management
services to customers;
• Ride along with vendors to perform on-site motor
inventories for customers;
• Help vendors use software tools to present
customers with the business case for proactive
planning.
• Who’s doing it:
– NYSERDA Premium Efficiency Motors Program
– National Grid Pilot Program
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Hire Contract Auditors
• Contractors are trained in the 1-2-3 Approach to
Motor Management and other MDM tools;
• Audits focus on opportunities for energy savings
through lighting projects, motors, compressed air,
and other sectors;
• Contractors with specific expertise in a non-motor
area often hire motor vendors to ride along and
enhance the value of service to the customer.
• Who’s doing it:
– National Grid Project Expediters (PEX)
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Educate Customers
• Program staff assesses the customer’s current motor
management practices compared to industry peers and
best practice.
• Program staff analyzes the customer’s motors list and
develops a business case that highlights savings
opportunities through motor management.
• Staff performs an on-site audit on motors of interest and
holds discussions with plant management and operations
team.
• Develop a customized motor management plan
operations guide and a report that justifies the adoption
of the guide.
• Who’s doing it:
– BC Hydro Power Smart
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Educate Vendors, Customers,
and Trade Organizations
• Host regional seminars, workshops, and/or
meetings;
• Invite largest customers, local vendors, and
members of relevant trade associations such as
building maintenance operators
• present information about how motor
management affects each group's business; present
information about your program and how to
connect to it.
• Who’s doing it:
– Austin Energy
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Program Tracking and Evaluation
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•
•
•
•
Customer satisfaction
Trade ally satisfaction
Customer energy savings
Net economic benefits
Cost and benefits summary
(including non-quantifiable benefits).
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Quantifying Non-Energy Benefits
• Non-Energy benefits include:
– Increased plant efficiency
– Worker productivity and safety,
– Reduced carbon emissions because of the
overall lower energy use.
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Greenhouse Gas
Equivalencies Calculator
http://www.epa.gov/cleanenergy/energy-resources/calculator.html
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Carbon Savings from
500,000 kWh
• Equal to 359 metric tons of CO2
• Reductions are equivalent to one of the
following;
–
–
–
–
CO2 emissions from 40, 758 gallons of gasoline consumed
CO2 emissions 835 from barrels of oil consumed
CO2 emissions from the electricity use of 49.5 homes for one year
CO2 emissions from the energy use of 32.7 homes for one year
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Overview of Motors/VFD
Tools and Resources
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Motor and VFD Case Studies
• Lumber/Wood Products: Alder Creek Lumber implemented
a decision to purchase NEMA Premium motors. The first
200 HP motor replaced will save close to $8300 per year – a
payback period of less than 12 months.
• Water/Wastewater: Officials running Frank L. VanLare
wastewater treatment facility believe NEMA Premium
motors help hold down energy costs and increase the
systems reliability.
• Other Industries: In one small manufacturing area at
Eastman Kodak’s Kodak Park, replacing motors with NEMA
Premium motors resulted in savings of 250,000 kWh
annually (or about $17,250).
www.motorsmatter.org/case_studies/alpha_list.html
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Examples of Motor
Replacement Decisions
Demonstrations and
Examples Using
Motor Master
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Motor Master Software
• Introduction
and
Overview
• Examples
using
Motor Master
Software
Estimated Annual Energy Savings with NEMA Premium ® Motors 1
TEFC
· 1800 RPM
· Full-load Operation
· Nominal Efficiency 3
Estimated Annual Energy Cost = (Hp x annual operating hours x cost of electricity x 0.746) / (efficiency)
Annual Operating Hours :
Enter Appropriate Values for:
8000
Cost of Electricity :
Motor
Size 2
(hp)
1
1.5
2
3
5
7.5
10
15
20
25
30
40
50
60
75
100
125
150
200
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Estimated Annual
Operating Costs
Pre-EPAct
Motors
$545
$792
$1,034
$1,540
$2,508
$3,665
$4,875
$7,236
$9,441
$11,695
$13,988
$18,526
$22,878
$27,305
$34,168
$45,261
$56,638
$67,381
$89,360
Estimated Annual
Energy Savings
Estimated Annual
Operating Costs
EPAct Motors
Pre-EPAct →
EPAct
EPAct Motors
$506
$746
$995
$1,432
$2,387
$3,501
$4,668
$6,886
$9,182
$11,303
$13,564
$17,968
$22,460
$26,779
$33,296
$44,207
$55,259
$65,962
$87,949
$38
$46
$39
$107
$120
$164
$207
$350
$259
$392
$424
$558
$418
$525
$871
$1,054
$1,378
$1,419
$1,411
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Estimated Annual
Energy Savings
EPAct →
NEMA Prem
$506
$746
$995
$1,432
$2,387
$3,501
$4,668
$6,886
$9,182
$11,303
$13,564
$17,968
$22,460
$26,779
$33,296
$44,207
$55,259
$65,962
$87,949
NEMA Prem
Motors
$489
$724
$966
$1,400
$2,334
$3,417
$4,556
$6,782
$8,984
$11,158
$13,390
$17,758
$22,104
$26,385
$32,843
$43,790
$54,738
$65,411
$86,852
Energy Efficient →
EPAct
NEMA Energy
Efficient Motors
hrs per year
¢ per kWh
Learn more about saving money
through sound motor management.
For additional tools and resources,
visit www.motorsmatter.org.
Estimated Annual
Operating Costs
Estimated Annual
Energy Savings
NEMA Prem
Motors
$489
$724
$966
$1,400
$2,334
$3,417
$4,556
$6,782
$8,984
$11,158
$13,390
$17,758
$22,104
$26,385
$32,843
$43,790
$54,738
$65,411
$86,852
Pre-EPAct →
NEMA Prem
$18
$22
$29
$32
$53
$84
$112
$104
$197
$145
$174
$210
$357
$395
$454
$417
$521
$551
$1,097
Pre-EPAct
Motors
$545
$792
$1,034
$1,540
$2,508
$3,665
$4,875
$7,236
$9,441
$11,695
$13,988
$18,526
$22,878
$27,305
$34,168
$45,261
$56,638
$67,381
$89,360
NEMA Prem
Motors
Energy Efficient →
NEMA Prem
Pre-EPAct
Motors
NEMA Prem
Motors
Energy Efficient →
NEMA Prem
$56
$68
$68
$139
$174
$248
$319
$454
$457
$537
$598
$768
$775
$920
$1,325
$1,471
$1,900
$1,969
$2,508
Size
(hp)
Pre-EPAct
Motors
NEMA Energy
Efficient Motors
250
$110,870
$109,937
$934
$109,937
$108,565
$1,371
$110,870
$108,565
$2,305
300
$132,763
$131,371
$131,371
$130,279
$130,279
$154,562
$153,266
$153,266
$151,992
$154,562
$151,992
400
$176,270
$175,161
$175,161
$173,705
$1,092
$1,275
$1,457
$132,763
350
$1,392
$1,296
$1,109
$176,270
$173,705
$2,484
$2,571
$2,565
450
$198,095
$197,057
$1,038
$197,057
$195,418
$1,639
$198,095
$195,418
$2,677
500
$220,105
$218,038
$2,068
$218,038
$217,131
$907
$220,105
$217,131
$2,974
1. This chart provides an estimated comparison of annual energy costs for Pre-EPAct, EPAct and NEMA Prem motors. Actual costs and savings may differ from the values shown.
2. The break in Motor Size between 200 and 250 hp occurs because EPAct applies to motors up to 200 hp. Above that value, NEMA's Energy Efficient Motor specification has been
used as the reference.
3. The nominal efficiency values used in these calculations are defined as follows: Pre-EPAct Motors: DOE's MotorMaster+ software version 4.00.01 (9/26/2003) "Average Standard
Efficiency" motor defaults ; EPAct Motors: Energy Policy Act of 1992 ; Energy Efficient Motors: NEMA MG 1-2003 Table 12-11 ; NEMA Premium Motors: NEMA MG 1-2003 Table 1212.
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Resources on Motors
• NEMA Premium: The energy specification tables for NEMA
Premium® motors are available on NEMA’s website
www.nema.org.
• Buying an Energy-Efficient Electric Motor
(U.S. Department of Energy, 1996)
www.eere.energy.gov/industry/bestpractices/motors.html
• Efficient Motors: Selection and Application
Considerations
www.cee1.org/ind/motrs/motr-broch.pdf.
• Replacing an Oversized and Underloaded Electric Motor
(U.S. Department of Energy)
www.eere.energy.gov/industry/bestpractices/motors.html
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Motor Repair Resources
• A Guide to AC Motor Repair and Replacement (EASA)
www.easa.com, under “Industry Info.”
• Guidelines for Maintaining Motor Efficiency During
• Rebuilding (EASA Tech Note No. 16)
www.easa.com, under “Industry Info.”
• Service Center Evaluation Guide (U.S. Department of
Energy, 2001)
www.eere.energy.gov/industry/bestpractices/techpubs_motors.html
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VFD Resources
• Application Guide for AC Adjustable Speed Drive Systems
(National Electrical Manufacturers Association, 2001,
www.nema.org, under “Standards.”
• National Summary of Energy-Efficiency Programs for Motors and
Drives
(Consortium for Energy Efficiency, 2004) www.motorsmatter.org to
download a PDF of the National Summary.
• Variable Frequency Drives: Technical Data Sheet (Wisconsin’s
Focus on Energy program, 2004)
www.focusonenergy.com/data/common/dmsFilesStaging/B_GC_MKFS_BPVariablefrequencydrives.pdf.
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VFD Resources (continued)
• Determining Electric Motor Load and Efficiency (U.S.
Department of Energy) Available online at
www.eere.energy.gov;
• Energy-Efficient Motor Systems: A Handbook on Technology,
Program, and Policy Opportunities (2nd ed.)
• Energy Management for Motor Driven Systems
(U.S. Department of Energy, 1997)
Length: 100 pages
www.eere.energy.gov/industry/bestpractices/motors.html.
• Order Number: DOE/MC-10021
• Optimizing Your Motor Driven System
(U.S. Department of Energy, 1996) Available online at
www.eere.energy.gov/industry/bestpractices/motors.html.
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Key Websites
• Motor Decisions Matter Sponsors: A list of MDM sponsors
is available at www.motorsmatter.org/sponsors/index.html.
• U.S. Department of Energy’s Office of Energy Efficiency
and Renewable Energy (EERE)
• The DOE’s EERE Information Center provides easy access to
motor planning resources and can field questions on DOE
products and services, including those focused on technical
questions about motor, steam, compressed air, and
combined heat and power systems. Call 877-337-3463 or
www.eere.energy.gov/industry/resources.
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Demand-Side Management
Technology Workshop:
Motors and Variable Frequency Drives
Sponsored by
Basin Electric Power Cooperative
with Western Area Power Administration
April 6, 2009
Bismarck, ND
23
www.johnsonconsulting.com